I. Overview In 1991, the British Welding Research Institute (TWI) invented the friction stir welding (FSW). Since then, based on the obvious advantages of this solid phase joining technology, for example, excellent joint force students can do without filling welding materials. There is no welding method and splash, little pre-weld preparation and welding deformation, and a lot of research and development work has been carried out in the international community. In addition, friction stir welding aluminum alloy materials can be welded, such as 2000 series, 5000 series and 7000 series high-strength aluminum alloy used in aviation and aerospace, and can also obtain high-quality connection by using this advanced welding method. Dave NICHOLAS of the British Welding Institute has determined that the friction stir welding process is the most attractive welding method since the advent of laser welding, and its emergence will revolutionize the connection technology of non-ferrous metals such as aluminum alloy.
In April 2002, Beijing Institute of Aeronautical Manufacturing Engineering and the British Welding Research Institute (TWI) formally signed a patent for friction stir welding patent technology, and obtained the exclusive second-class license granting of patented friction stir welding technology, which opened for the Chinese market. Research and development of friction stir welding technology and the door to large-scale industrial applications.
Second, the application status of aluminum alloy friction stir welding
Friction stir welding technology has many unique advantages. The connection of light alloy materials (such as aluminum, copper, magnesium, zinc, etc.) has incomparable advantages in welding methods, mechanical properties and production efficiency. Friction stir welding is a solid phase joining method. The welded joint has excellent mechanical properties and small welding deformation. It does not need to add protective gas and welding wire during welding. It has no melting, soot, splash and arc. It is an environmentally friendly type. New connection technology. This is indeed the case. In the short span of FSW technology, great progress has been made in welding mechanisms, applicable materials, welding equipment and engineering applications. Friction stir welding technology was originally used to solve the welding of aluminum alloys, magnesium alloys and zinc alloys. Regarding the characteristics and applications of the friction stir welding process, the British Welding Research Institute has conducted a lot of research, and applied for worldwide patent protection in 1993 and 1995. At present, the institute is mainly engaged in research and development of friction stir welding technology in the form of group sponsorship or cooperation (TWI GSP project) in cooperation with welding equipment manufacturers such as aviation, aerospace, shipbuilding, high-speed trains and automobiles, and international large companies. , continue to expand its range of applications.
Research projects currently sponsored by industrial companies include: friction stir welding of large-thickness aluminum alloys, friction stir welding of steel, friction stir welding of titanium alloys, and friction stir welding of automotive lightweight components. The Edison Welding Institute (EWI) in the United States works closely with TWI and is also conducting research on the FSW process. Lockheed of the United States. Martin Aerospace, Marshall Space Flight Center, US Naval Research Year, Dartmuth University, Stuttgart University in Germany, Adelaide University in Australia, and the Australian Welding Institute all have specialized research on friction stir welding from different angles.
1 Application of aluminum alloy friction stir welding in aerospace field With the further research on friction stir welding, friction stir welding equipment has gradually moved from the laboratory to commercial use. TWI applied this technology to produce three 2000 series aluminum alloy spacecraft fuel tanks for Boeing; Lockheed, USA. Martin, Boeing-McDow, Rockwell Group, Edison Welding Institute and many other organizations are currently working on the research, application evaluation and development of friction stir welding. Structures suitable for welding with FSW technology in the aerospace industry include: skins for military or civil aircraft, cryogenic fuel tanks in spacecraft, aircraft fuel tanks, auxiliary tanks for military aircraft, military or scientific detection rockets, etc.; Lockheed, USA. Martin Aerospace used this technology to weld cryogenic vessels that store liquid oxygen outside the space shuttle; the Marshall Space Flight Center has also used this technology to weld large cylindrical vessels.
Boeing invested millions of dollars to build a large-scale dedicated friction stir welder for large-scale cryogenic fuel containers for Delta launch vehicles. BAE Airbus is conducting method, performance and feasibility verification of FSW technology for production. For medium and large commercial aircraft, the friction stir welder is manufactured by GRAWFORD-SWIFT, located in Helix, and is said to be the most powerful welder in Europe. The US ECLIPSE (Lunar Eclipse) airline will use the FSW to build a medium-sized aircraft with a 10.86 m long and a wingspan of 11.88 m. The company estimates that the FSW can reduce the assembly time of the ribs and frames on the fuselage wall panel by 80%, reducing the aircraft cost to $837,000. The main structural parts and skins of the aircraft are all manufactured by the latest international connection technology, friction stir welding technology. The fuselage of the passenger aircraft is basically made by friction stir welding, including aircraft skin, ribs and strings. Support, aircraft floor and assembly of structural parts.
The application of friction stir welding is mainly used to improve production efficiency and reduce manufacturing cost. The friction stir welding process for aviation structural parts is jointly developed by TWI and American ALCOA company, and then applied to the welding of ECLIPSE500 aircraft structural parts. In September 2000, the company passed the preliminary design evaluation and certification of the Aircraft Safety Committee. In June 2001, the feasibility of aircraft manufacturing for friction stir welding was determined. In 2001, the friction stir welding aircraft structural parts were manufactured. The first in June 2002. Flying, and from June 29th to July 1st to show the public that this new type of aircraft has hundreds of customers vying to order this new type of humble, cut-off business aircraft, the aircraft is expected in 2003 Flight certification was carried out in August and was used by users in August 2003.
2 Application of aluminum alloy friction stir welding in the field of shipbuilding Currently, based on the great advantages of friction stir welding in welding methods, mechanical properties, manufacturing costs and environment, and potential industrial application prospects, in the field of shipbuilding, mixing Friction welding has been thoroughly researched and developed. Shipbuilding not only requires an increase in speed, but also requires an increase in unit price load performance, so the ship is manufactured with as much aluminum alloy as possible to reduce the weight of the ship. However, the traditional joining method of aluminum alloy materials is rivet joint and arc welding joint. Riveting increases the manufacturing time, manpower and material usage, while aluminum alloy is prone to deformation, defects and soot during welding, and also limits arc welding. The use of aluminum alloy components, so with the development of friction stir welding technology, the use of friction stir welding to achieve high integration of pre-formed modular manufacturing to replace the traditional ship to the plate - reinforcement structure manufacturing, is the shipbuilding technology The inevitable and revolutionary progress of development.
The application of friction stir welding on marine light alloy preformed structural parts has obvious advantages in appearance, weight, performance, cost and manufacturing time. It can be used not only for the manufacture of marine light alloy structural parts, but also for on-site use. Assembling, it provides a new connection method for modern shipbuilding. It is a leap forward in the development of modern welding technology to inform friction stir welding instead of welding to realize the manufacture of light alloy structural parts.
FSW technology has broad application prospects in the shipbuilding, marine industry and aerospace industries. The structures suitable for welding with FSW technology include: tailor welding of decks, siding, partitions, etc., welding of aluminum extrusions, hull and Welding of reinforcements, welding of helicopter landing platforms, etc. This technology has been used to weld aluminum alloy structural members with a length of 20 m in the speedboat, with a total weld length of more than 500 km.
Third, the development trend of aluminum alloy friction stir welding
In China, Beijing Aerospace Manufacturing Engineering Research Institute and TWI's Stirring Test Welding Technology Cooperation Center - China Friction Stir Welding Center, the basic method of friction stir welding, material application research, development, friction stir welding equipment design, manufacturing and Great progress has been made in sales and other aspects.
(1) At present, the center is working on friction stir welding in the manufacture of space rocket cylinders, friction stir welding between aircraft frames, skins and structures, ship light alloy manufacturing and rapid manufacturing of aluminum alloy profiles for high-speed trains. Comprehensive research and engineering research. In addition, while undertaking national defense research and final assembly projects, it has also strengthened horizontal cooperation and technical cooperation with enterprises and universities.
(2) Three types of 6 types of friction stir welding equipment have been designed in the manufacture of friction stir welding equipment, and in March 2003, two specialized specializations were delivered for Harbin Institute of Technology and East China Shipbuilding Institute. Friction stir welding equipment.
(3) In engineering applications, aluminum alloy friction stir welding will be first applied in power transmission and transformation, high-speed trains, new-generation fighters and new launch vehicles.
Fourth, the conclusion
Friction stir welding as a new type of welding technology will revolutionize the connection manufacturing of light alloy materials such as aluminum alloy. Based on the breakthrough of the welding method in this connection technology, it is expected that the friction stir welding technology will be for airplanes, rockets, and high speed. The design and manufacturing baselines of military and civilian products such as trains, missile speedboats, and all-aluminum tanks have undergone fundamental changes.
In April 2002, Beijing Institute of Aeronautical Manufacturing Engineering and the British Welding Research Institute (TWI) formally signed a patent for friction stir welding patent technology, and obtained the exclusive second-class license granting of patented friction stir welding technology, which opened for the Chinese market. Research and development of friction stir welding technology and the door to large-scale industrial applications.
Second, the application status of aluminum alloy friction stir welding
Friction stir welding technology has many unique advantages. The connection of light alloy materials (such as aluminum, copper, magnesium, zinc, etc.) has incomparable advantages in welding methods, mechanical properties and production efficiency. Friction stir welding is a solid phase joining method. The welded joint has excellent mechanical properties and small welding deformation. It does not need to add protective gas and welding wire during welding. It has no melting, soot, splash and arc. It is an environmentally friendly type. New connection technology. This is indeed the case. In the short span of FSW technology, great progress has been made in welding mechanisms, applicable materials, welding equipment and engineering applications. Friction stir welding technology was originally used to solve the welding of aluminum alloys, magnesium alloys and zinc alloys. Regarding the characteristics and applications of the friction stir welding process, the British Welding Research Institute has conducted a lot of research, and applied for worldwide patent protection in 1993 and 1995. At present, the institute is mainly engaged in research and development of friction stir welding technology in the form of group sponsorship or cooperation (TWI GSP project) in cooperation with welding equipment manufacturers such as aviation, aerospace, shipbuilding, high-speed trains and automobiles, and international large companies. , continue to expand its range of applications.
Research projects currently sponsored by industrial companies include: friction stir welding of large-thickness aluminum alloys, friction stir welding of steel, friction stir welding of titanium alloys, and friction stir welding of automotive lightweight components. The Edison Welding Institute (EWI) in the United States works closely with TWI and is also conducting research on the FSW process. Lockheed of the United States. Martin Aerospace, Marshall Space Flight Center, US Naval Research Year, Dartmuth University, Stuttgart University in Germany, Adelaide University in Australia, and the Australian Welding Institute all have specialized research on friction stir welding from different angles.
1 Application of aluminum alloy friction stir welding in aerospace field With the further research on friction stir welding, friction stir welding equipment has gradually moved from the laboratory to commercial use. TWI applied this technology to produce three 2000 series aluminum alloy spacecraft fuel tanks for Boeing; Lockheed, USA. Martin, Boeing-McDow, Rockwell Group, Edison Welding Institute and many other organizations are currently working on the research, application evaluation and development of friction stir welding. Structures suitable for welding with FSW technology in the aerospace industry include: skins for military or civil aircraft, cryogenic fuel tanks in spacecraft, aircraft fuel tanks, auxiliary tanks for military aircraft, military or scientific detection rockets, etc.; Lockheed, USA. Martin Aerospace used this technology to weld cryogenic vessels that store liquid oxygen outside the space shuttle; the Marshall Space Flight Center has also used this technology to weld large cylindrical vessels.
Boeing invested millions of dollars to build a large-scale dedicated friction stir welder for large-scale cryogenic fuel containers for Delta launch vehicles. BAE Airbus is conducting method, performance and feasibility verification of FSW technology for production. For medium and large commercial aircraft, the friction stir welder is manufactured by GRAWFORD-SWIFT, located in Helix, and is said to be the most powerful welder in Europe. The US ECLIPSE (Lunar Eclipse) airline will use the FSW to build a medium-sized aircraft with a 10.86 m long and a wingspan of 11.88 m. The company estimates that the FSW can reduce the assembly time of the ribs and frames on the fuselage wall panel by 80%, reducing the aircraft cost to $837,000. The main structural parts and skins of the aircraft are all manufactured by the latest international connection technology, friction stir welding technology. The fuselage of the passenger aircraft is basically made by friction stir welding, including aircraft skin, ribs and strings. Support, aircraft floor and assembly of structural parts.
The application of friction stir welding is mainly used to improve production efficiency and reduce manufacturing cost. The friction stir welding process for aviation structural parts is jointly developed by TWI and American ALCOA company, and then applied to the welding of ECLIPSE500 aircraft structural parts. In September 2000, the company passed the preliminary design evaluation and certification of the Aircraft Safety Committee. In June 2001, the feasibility of aircraft manufacturing for friction stir welding was determined. In 2001, the friction stir welding aircraft structural parts were manufactured. The first in June 2002. Flying, and from June 29th to July 1st to show the public that this new type of aircraft has hundreds of customers vying to order this new type of humble, cut-off business aircraft, the aircraft is expected in 2003 Flight certification was carried out in August and was used by users in August 2003.
2 Application of aluminum alloy friction stir welding in the field of shipbuilding Currently, based on the great advantages of friction stir welding in welding methods, mechanical properties, manufacturing costs and environment, and potential industrial application prospects, in the field of shipbuilding, mixing Friction welding has been thoroughly researched and developed. Shipbuilding not only requires an increase in speed, but also requires an increase in unit price load performance, so the ship is manufactured with as much aluminum alloy as possible to reduce the weight of the ship. However, the traditional joining method of aluminum alloy materials is rivet joint and arc welding joint. Riveting increases the manufacturing time, manpower and material usage, while aluminum alloy is prone to deformation, defects and soot during welding, and also limits arc welding. The use of aluminum alloy components, so with the development of friction stir welding technology, the use of friction stir welding to achieve high integration of pre-formed modular manufacturing to replace the traditional ship to the plate - reinforcement structure manufacturing, is the shipbuilding technology The inevitable and revolutionary progress of development.
The application of friction stir welding on marine light alloy preformed structural parts has obvious advantages in appearance, weight, performance, cost and manufacturing time. It can be used not only for the manufacture of marine light alloy structural parts, but also for on-site use. Assembling, it provides a new connection method for modern shipbuilding. It is a leap forward in the development of modern welding technology to inform friction stir welding instead of welding to realize the manufacture of light alloy structural parts.
FSW technology has broad application prospects in the shipbuilding, marine industry and aerospace industries. The structures suitable for welding with FSW technology include: tailor welding of decks, siding, partitions, etc., welding of aluminum extrusions, hull and Welding of reinforcements, welding of helicopter landing platforms, etc. This technology has been used to weld aluminum alloy structural members with a length of 20 m in the speedboat, with a total weld length of more than 500 km.
Third, the development trend of aluminum alloy friction stir welding
In China, Beijing Aerospace Manufacturing Engineering Research Institute and TWI's Stirring Test Welding Technology Cooperation Center - China Friction Stir Welding Center, the basic method of friction stir welding, material application research, development, friction stir welding equipment design, manufacturing and Great progress has been made in sales and other aspects.
(1) At present, the center is working on friction stir welding in the manufacture of space rocket cylinders, friction stir welding between aircraft frames, skins and structures, ship light alloy manufacturing and rapid manufacturing of aluminum alloy profiles for high-speed trains. Comprehensive research and engineering research. In addition, while undertaking national defense research and final assembly projects, it has also strengthened horizontal cooperation and technical cooperation with enterprises and universities.
(2) Three types of 6 types of friction stir welding equipment have been designed in the manufacture of friction stir welding equipment, and in March 2003, two specialized specializations were delivered for Harbin Institute of Technology and East China Shipbuilding Institute. Friction stir welding equipment.
(3) In engineering applications, aluminum alloy friction stir welding will be first applied in power transmission and transformation, high-speed trains, new-generation fighters and new launch vehicles.
Fourth, the conclusion
Friction stir welding as a new type of welding technology will revolutionize the connection manufacturing of light alloy materials such as aluminum alloy. Based on the breakthrough of the welding method in this connection technology, it is expected that the friction stir welding technology will be for airplanes, rockets, and high speed. The design and manufacturing baselines of military and civilian products such as trains, missile speedboats, and all-aluminum tanks have undergone fundamental changes.
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